Catalytic upcycling process

Abstract

Provided is a process for producing one or more aromatic compounds comprising exposing a feed composition comprising at least one plastic to microwave radiation in the presence of a solid catalyst composition, wherein the solid catalyst composition comprises a solid acid catalyst and a carbon source. Also provided is a solid catalyst composition suitable for use in said process and for upcycling plastic.

1 . A process for producing one or more aromatic compounds comprising exposing a feed composition comprising at least one plastic to microwave radiation in the presence of a solid catalyst composition, wherein the solid catalyst composition comprises a solid acid catalyst and a carbon source. 
     
     
         2 . A process according to  claim 1  wherein the aromatic compounds comprise a mixture of benzene, toluene and xylene isomers. 
     
     
         3 . A process according to  claim 1  wherein the solid acid catalyst is a zeolite. 
     
     
         4 . A process according to  claim 3  wherein the zeolite is selected from an acidic aluminosilicate zeolite, an acidic silicon aluminium phosphate (SAPO) zeolite or a metallosillicate analogue of zeolite. 
     
     
         5 . A process according to  claim 3  wherein the zeolite is a ZSM-5 zeolite. 
     
     
         6 . A process according to  claim 3  wherein the zeolite has a Si:Al ratio about 20 to about 60. 
     
     
         7 . A process according to  claim 1  wherein the carbon source is selected from a carbon black, activated carbon, graphene, graphite, carbon nanofiber, carbon nanotube, carbon nanohorn, carbon nanoballoon, fullerene, carbides, charcoal, coal or combinations thereof. 
     
     
         8 . A process according to  claim 7  wherein the carbon source is a carbon black. 
     
     
         9 . A process according to  claim 1  wherein the carbon source is present from about 1 wt. % to about 50 wt. % of the total weight of the solid catalyst. 
     
     
         10 . A process according to  claim 1  wherein the solid catalyst composition consists of a ZSM-5 zeolite and a carbon black in a ratio of about 95:5 to about 90:10. 
     
     
         11 . A process according to  claim 1  wherein the feed composition comprises about 90% or more of one or more plastics. 
     
     
         12 . A process according to  claim 1  wherein the feed composition comprises at least one of polyethylene and polypropylene. 
     
     
         13 . A process according to  claim 1  wherein the ratio of feed composition to solid catalyst composition is about 50:1 to about 1:10. 
     
     
         14 . A process according to  claim 13  wherein the ratio of feed composition to solid catalyst composition is about 3:1 to about 1:1. 
     
     
         15 . A process according to  claim 1  wherein the process is carried out in an atmosphere substantially free of oxygen, and/or substantially free of water. 
     
     
         16 . A solid catalyst composition comprising a solid acid catalyst in admixture with a carbon source. 
     
     
         17 . A solid catalyst composition according to  claim 16  wherein the solid acid catalyst is a zeolite. 
     
     
         18 . A solid catalyst composition according to  claim 16  wherein the carbon source is selected from a carbon black, activated carbon, graphene, graphite, carbon nanofiber, carbon nanotube, carbon nanohorn, carbon nanoballoon, fullerene, carbides, charcoal, coal or combinations thereof. 
     
     
         19 . A solid catalyst composition according to  claim 16  wherein the solid catalyst consists of a ZSM-5 zeolite and a carbon black in a ratio of about 95:5 to about 90:10. 
     
     
         20 . Use of a solid catalyst composition according to  claim 16  for upcycling plastic and/or the production of aromatic compounds.